ClusterTruck; because that’s what it is

[clay68c10]

First I needed to strip the front edge and see what I'm dealing with. None of it looked bad from the outside.
Luckily, the back side if the hood makes it clear where the holes go. It's a double wall so the inner holes were still there.
I used my square and a "precise" eyeball and marked the locations.
Then I grabbed one of my smallest drill bits and made a starter hole. I figured (correctly) that the little guy wouldn't grab and tear. I could feel it want to get off center sometimes, but it didn't have enough flute to grab sideways.
Now I could look from the back side and verify that I had the hole centered, and if not, which direction I needed to go. All the holes were very close.

[clay68c10]

At this point I was ready to enlarge the hole.
First I carefully used a thin stepped drill. It worked ok initially, but when it caught on the uneven back side the tip broke off. No bueno. At least it didn't harm anything.
Next up was a thin tapered die grinder bit. I used it in my drill vs a die grinder. That gave me better control and it didn't want to bounce around like they sometimes do in thin material at high speed.
It ended up being the best tool for the job, hands down. It didn't cut too quickly, it cut evenly, and it didn't catch. The only thing it did on the thicker weld globs was cut slower because the material was thicker.
Success!

[ryans69chevy]

That color looks so good. Pickup is coming together nicely. Where did you get that sound deadening/heat shield material? I found someone local I can get dynamat. Im looking for a product to put between my roof panels since I have the roof skin off. Was hoping to find a product for both sound and heat.

[clay68c10]

Originally Posted by ryans69chevy

That color looks so good. Pickup is coming together nicely. Where did you get that sound deadening/heat shield material? I found someone local I can get dynamat. Im looking for a product to put between my roof panels since I have the roof skin off. Was hoping to find a product for both sound and heat.

Thanks!
I bought my sound deadening directly from siless. They had and may still have free shipping. I’ve heard good things about their products.